Flexomix continuous agglomeration system

The Flexomix continuous agglomeration system is a combination of two proven Hosokawa technologies: the Flexomix continuous mixer/agglomerator and the Schugi^® fluid bed dryer and cooler. This combined design provides optimal process control and makes it the ultimate powder processing solution.

The Flexomix agglomeration system is controlled using a state-of-the-art integrated control system based on PLC and SCADA systems. It produces instant agglomerates with an open, raspberry-like structure, good solubility and good flow characteristics. The fluid bed dryer is specially designed for this system as a stationary unit without any moving parts, making it perfect for scaling up to almost any size.

The Flexomix continuous agglomeration system is a powerful combination of a number of functionalities:

Powder handling system
Powder dosing system
Binder dosing system(s): water, steam, and other liquids
Schugi® Flexomix mixer and agglomerator (FX),
Schugi® Fluid Bed Dryer and Cooler (FBD)
Air system including blower and heating/cooling equipment
Air exhaust system including cyclone and filter
Product classification and size crusher (if necessary)
State-of-the-art integrated control system

This combination means that base powders can be fed as a mixture or as multiple powders in parallel. An accurate, gravimetrical powder feeding subsystem ensures a constant powder/liquid ratio and a liquid dosing skid ensures accurate flow control and a constant powder/liquid ratio in the agglomerator. This liquid skid can be equipped with a stirrer or a heated tank for example, or in the case of solution binders, a preparation tank.

Flexomix mixer/agglomerator

Powders and liquids can be fed into the unit through top inlet(s) using air atomizers which combine with turbulent air flow inside the mixer’s vertical chamber, mixes powdery and liquid particles intensively and instantaneously.

The Flexomix has been designed to be compact whilst allowing for homogeneous mixing of powders and liquids at capacities of up to 40,000 kg/h. To achieve this, the Flexomix has a flexible mixing chamber and a shaft with pitch-adjustable mixing blades that rotate at high speed. The resulting granulates have a porous, raspberry like structure in particle sizes of 0.1 to 1.2 mm and with a D50 between 300 and 700 micron at low to medium density.

Schugi fluid bed dryer

The wet granulates from the Flexomix are then processed in a Schugi^® fluid bed dryer which is divided into several compartments. The front end compartments are used for drying; the rear for cooling. Product height in the bed can be altered from between 100 and about 500 mm (average 300 mm), and depending on the application, variable residence times can be achieved by adjusting the bed height.

The Flexomix agglomeration system has an air system and air exhaust system including cyclone and filter, as well as a one or two-deck sieve and an oversize crusher for product classification.

Continuous process
Compact design in capacities between 50 kg/h and 40,000 kg/h
Separate operating units for agglomeration and drying/cooling for optimal process control
Multiple simultaneous liquid addition possible
Vertical mixer/agglomerator with self-cleaning mixing chamber
Integrated system approach

Schugi fluid bed dryers/coolers are available in sizes (air distribution plate area) ranging from 0.25 m² to > 20 m². The required size of the dryer/cooler is generally determined in our test centre and depends on product throughput, evaporation capacity, particle size distribution, air temperatures and final product temperature.

The Flexomix mixer/agglomerator is available in six sizes. Their typical characteristics are described below. Please note that these values are indicative only. Detailed information is available on request.

Model	[-]	FXD-100	FXD-160	FXD-220	FXD-250	FXD-335	FXD-400
Length	[mm]	520	702	976	976	1270	1270
Width	[mm]	650	620	880	880	1100	1100
Height incl. motor	[mm]	1265	1500	1967	1967	2770	2910
Capacity (bulk density 0.5 kg/l)	[kg/h]	100 - 400	250 - 1000	800 - 2500	2000 - 4000	3000 - 10,000	8000 - 40,000
Typical motor power	[kW]	3	7.5	7.5 - 10	11 - 15	22 - 45	37 - 75